Classifications

• • C—CHEMISTRY; METALLURGY
  • C01—INORGANIC CHEMISTRY
  • C01G—COMPOUNDS CONTAINING METALS NOT COVERED BY SUBCLASSES C01D OR C01F
  • C01G49/00—Compounds of iron
• • G—PHYSICS
  • G11—INFORMATION STORAGE
  • G11B—INFORMATION STORAGE BASED ON RELATIVE MOVEMENT BETWEEN RECORD CARRIER AND TRANSDUCER
  • G11B5/00—Recording by magnetisation or demagnetisation of a record carrier; Reproducing by magnetic means; Record carriers therefor
  • G11B5/62—Record carriers characterised by the selection of the material
  • G11B5/68—Record carriers characterised by the selection of the material comprising one or more layers of magnetisable material homogeneously mixed with a bonding agent
  • G11B5/70—Record carriers characterised by the selection of the material comprising one or more layers of magnetisable material homogeneously mixed with a bonding agent on a base layer
  • G11B5/706—Record carriers characterised by the selection of the material comprising one or more layers of magnetisable material homogeneously mixed with a bonding agent on a base layer characterised by the composition of the magnetic material
  • G11B5/70605—Record carriers characterised by the selection of the material comprising one or more layers of magnetisable material homogeneously mixed with a bonding agent on a base layer characterised by the composition of the magnetic material metals or alloys
  • G11B5/70615—Record carriers characterised by the selection of the material comprising one or more layers of magnetisable material homogeneously mixed with a bonding agent on a base layer characterised by the composition of the magnetic material metals or alloys containing Fe metal or alloys
• • C—CHEMISTRY; METALLURGY
  • C01—INORGANIC CHEMISTRY
  • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
  • C01B32/00—Carbon; Compounds thereof
  • C01B32/90—Carbides
  • C01B32/914—Carbides of single elements
• • C—CHEMISTRY; METALLURGY
  • C01—INORGANIC CHEMISTRY
  • C01P—INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
  • C01P2002/00—Crystal-structural characteristics
  • C01P2002/70—Crystal-structural characteristics defined by measured X-ray, neutron or electron diffraction data
  • C01P2002/72—Crystal-structural characteristics defined by measured X-ray, neutron or electron diffraction data by d-values or two theta-values, e.g. as X-ray diagram
• • C—CHEMISTRY; METALLURGY
  • C01—INORGANIC CHEMISTRY
  • C01P—INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
  • C01P2004/00—Particle morphology
  • C01P2004/54—Particles characterised by their aspect ratio, i.e. the ratio of sizes in the longest to the shortest dimension
• • C—CHEMISTRY; METALLURGY
  • C01—INORGANIC CHEMISTRY
  • C01P—INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
  • C01P2004/00—Particle morphology
  • C01P2004/60—Particles characterised by their size
  • C01P2004/61—Micrometer sized, i.e. from 1-100 micrometer
• • C—CHEMISTRY; METALLURGY
  • C01—INORGANIC CHEMISTRY
  • C01P—INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
  • C01P2004/00—Particle morphology
  • C01P2004/60—Particles characterised by their size
  • C01P2004/62—Submicrometer sized, i.e. from 0.1-1 micrometer

Definitions

• the present invention relates to a process for preparing iron carbide fine particles.
• acicular particles containing iron carbide are prepared by contacting acicular iron oxyhydroxide or acicular iron oxide with CO or a mixture of CO and H2 at 250 to 400 °C and that the resulting particles are stable chemically, have a high coercive force and are useful as a magnetic material for magnetic recording media.
• JP-B as used herein means an "examined published Japanese patent application” and "JP-A” as used herein means an "unexamined published Japanese patent application”.
• iron carbide fine particles are generally used as a coating-type magnetic recording medium, they are required to have characteristics as a coating material like a pigment. However, iron carbide fine particles would be sintered or deformed during reduction or carburizing step. Therefore, the starting particles are coated with a silicon compound or aluminum compound and then reduced and carburized. Although the particles are prevented from sintering or deformation, a large amount of carbon deposits on the resulting particles to cause deterioration of the magnetic characteristics.
• JP-A-1-192713 discloses a process for preparing iron carbide fine particles which are less in deterioration of the magnetic characteristics.
• iron carbide fine particles are obtained by contacting at 250 to 400 °C an iron compound selected from the group consisting of iron oxyhydroxide fine particles and iron oxide fine particles with a reducing-and-carburizing agent containing carbon atom such as CO, the iron compound being, prior to the above contact, coated with nickel compound, copper compound or manganese compound and then coated with silicon compound or aluminum compound. With this process are obtained fine particles which are improved in coercive force and saturation magnetization.
• An object of the invention is to provide a process for preparing iron carbide fine particles which are small in deposition of free carbon on the resulting iron carbide particles and high in saturation magnetization.
• the present invention provides a process for preparing iron carbide fine particles having an average particle size (long axis) of 0.1 to 2 ⁇ m and an average axial ratio of 3 to 20, which comprises,
• the aluminum compound or silicon compound which is added to stabilizing the shape of the starting iron compound, acts as a catalyst for depositing carbon in the reduction with CO.
• the iron compound or cobalt compound is effective to prevent the above deposition of carbon.
• Examples of preferred iron oxyhydroxides are ⁇ - FeOOH (goethite), ⁇ -FeOOH (akaganite) and ⁇ -FeOOH (lepidocrosite).
• Examples of preferred iron oxides are ⁇ - Fe2O3 (hematite) ⁇ -Fe2O3 (maghemite) and Fe3O4 (magnetite).
• ⁇ -Fe2O3 or ⁇ -Fe2O3 is, for example, one prepared by heating ⁇ -FeOOH, ⁇ -FeOOH or ⁇ -FeOOH at about 200 to about 350 °C, followed by dehydrating it, ⁇ -Fe2O3 or ⁇ -Fe2O3 prepared by heating the resulting product further at about 350 to about 900 °C to compact the crystals, and others.
• ⁇ -FeOOH is preferably treated with an aqueous solution of alkaline compound.
• the above-mentioned Fe3O4 can be prepared by contacting an iron oxide other than Fe3O4 or iron oxyhydroxide with a reducing-and-carburizing agent containing carbon atom or a reducing agent which does not contain carbon atom, or a mixture thereof, although the Fe3O4 is not limited to one prepared in those methods.
• a reducing-and-carburizing agent containing carbon atom or a mixture thereof with a reducing agent which does not contain carbon atom is contacted with an iron oxyhydroxide or iron oxide other than Fe3O4 to prepare Fe3O4
• the same contact conditions as those in the process (b) of the invention can also be employed except for the time condition.
• the Fe3O4 formed can be subsequently held in contact with the gas under the same conditions as in the preceding reaction without any interruption to obtain the desired particles of the invention.
• the starting iron oxyhydroxides or iron oxides can be those at least 3, preferably 3 to 20, in average axial ratio and having an average particle size (long axis) of up to 2 ⁇ m, preferably 0.1 to 2 ⁇ m, most preferably 0.1 to 1.0 ⁇ m.
• the particles produced are slightly smaller than, but almost unchanged from, the starting material in average axial ratio and in average particle size, so that the particles of the invention in general preferably have such sizes.
• the iron oxyhydroxide or iron oxide to be used as a starting material in the process for producing particles of the invention may contain a small amount or small amounts of a compound, such as oxide or carbonate of copper, magnesium, manganese or nickel; silicon oxide, potassium salt, sodium salt, etc., which are added when preparing the iron oxyhydroxide or iron oxide, insofar as the starting material chiefly comprises an iron oxyhydroxide or iron oxide.
• a compound such as oxide or carbonate of copper, magnesium, manganese or nickel; silicon oxide, potassium salt, sodium salt, etc.
• the starting iron oxyhydroxide preferably has a pH of at least 5 on the surface thereof as disclosed in JP-A-60-108309. In this case are produced particles having a higher coercive force.
• the starting iron oxyhydroxide having a pH of less than 5 can be used after it is increased to at least 5 in pH by contacting with an aqueous solution of an alkali compound (eg, sodium hydroxide, potassium hydroxide, ammonium hydroxide). Further, alkali-treated iron oxide can also be used.
• an alkali compound eg, sodium hydroxide, potassium hydroxide, ammonium hydroxide.
• the starting material can be treated with an alkaline compound by contacting the material with an aqueous solution of sodium hydroxide, potassium hydroxide, ammonium hydroxide and like alkaline compound (e.g., with an aqueous solution having a pH of at least 8, preferably at least 10), stirring for 30 minutes to 1 hour when required, filtering the mixture and drying.
• an aqueous solution of sodium hydroxide, potassium hydroxide, ammonium hydroxide and like alkaline compound e.g., with an aqueous solution having a pH of at least 8, preferably at least 10
• the surface pH is defined as a value which is obtained by boiling 5g of a sample in 100cc of distilled water for one hour, cooling the solution to room temperature, allowed to stand for one hour and measuring a pH of the resulting supernatant with a pH meter.
• the particles of the above iron oxyhydroxide or iron oxide (hereinafter both compounds may be referred to as "starting iron compound”) is coated with iron compound or iron compound and cobalt compound, and with aluminum compound or silicon compound.
• iron compounds are iron chloride, iron nitrate and iron sulfate.
• Cobalt compounds include cobalt chloride, cobalt nitrate and cobalt sulfate.
• silicon compounds are sodium orthosilicate, sodium metasilicate, potassium metasilicate and water glass, which includes various compositions.
• Aluminum compounds include aluminum sulfate, aluminum nitrate, aluminum chloride, various aluminum alum, sodium aluminate and potassium aluminate.
• Each of those metal compounds can be coated on the surface of the starting iron compound, for example, by adding an aqueous solution of the above compound to a dispersion of the starting iron compound and then neutralizing the mixture.
• the amount for coating of each of the metal compound is 0.01 to 10 % by weight in terms of the metal element based on the weight of the iron oxyhydroxide or iron oxide in terms of Fe2O3.
• typical examples of the reducing agent which does not contain carbon atom are H2, NH2NH2, etc.
• the reducing-and-carburizing agent containing carbon atom at least one of the following compounds can be used.
• the reducing agent which does not contain carbon atom can be used as it is or as diluted.
• diluents are N2, CO2, argon, helium, etc.
• the dilution ratio is suitably selected but is preferably up to about 10 times (by volume).
• the contacting temperature, contacting time, gas flow rate and other conditions depend, for example, on the production history, average axial ratio, average particle size and specific surface area of the starting iron compound.
• the preferred contacting temperature is about 200 to about 700 °C, preferably about 300 to about 400 °C.
• the preferred contacting time is about 0.5 to about 6 hours.
• the preferred gas flow rate (excluding diluent) is about 1 to about 1000 ml S.T.P./min per gram of the starting iron compound.
• the contacting pressure inclusive of that of the diluent is usually 0,1 to 0,2 MPa (1 to 2 atm). although not particularly limitative.
• the reducing-and-carburizing agent containing carbon atom or a mixture thereof with the reducing agent which does not contain carbon atom can be used as it is or as diluted.
• the mixing ratio of the reducing-and-carburizing agent to the reducing agent is suitably selected but is preferably up to 1 to 5 by volume.
• Contact conditions are also suitably selected but the preferred contacting temperature is about 250 to about 400 °C, more preferably about 300 to about 400 °C.
• the preferred contacting time is about 0.5 to 6 hours when the contact in (a) is conducted, and about 1 to about 12 hours when the contact in (a) is not conducted.
• the preferred gas flow rate (excluding diluent) is about 1 to about 1000 ml S.T.P./min per gram of the starting iron compound.
• the contacting pressure inclusive of that of the diluent is usually 0,1 to 0,2 MPa (1 to 2 atm). although not particularly limitative.
• the particles obtained by the present invention are in the form of generally uniform particles when observed under an electron microscope.
• the particles are present as primary acicular particles and have the same particulate form as the particles of the starting iron compound.
• the particles obtained by the process are found to contain carbon by elementary analysis and to contain an iron carbide by its X-ray diffraction pattern, which exhibits plane spacings at 2.28 ⁇ , 2.20 ⁇ , 2.08 ⁇ , 2.05 ⁇ and 1.92 ⁇ .
• Such pattern corresponds to Fe5C2 .
• the iron carbide component of the present invention chiefly comprises Fe5C2 , with Fe2C, Fe20C9 (Fe2.2C), Fe3C, Fe7C3, etc. present conjointly therewith in some cases. It is suitable to represent the iron carbide as FexC (2 ⁇ x ⁇ 3).
• the iron carbide fine particles of the present invention are useful as a magnetic material for magnetic recording as is apparent from the foregoing characteristics, etc., while the use thereof is not limited thereto.
• the particulate material is usable as a catalyst for preparing lower aliphatic hydrocarbons from CO and H2.
• present iron carbide fine particles are useful as a starting material for producing metal iron fine particles containing carbon.
• Coercive force (Hc, Oe), saturation magnetization ( ⁇ s, e.m.u./g) and square ratio (Sq) are measured in a magnetic field with a strength of 5 kOe, using a gauss meter equipped with a Hall-effect element and the powder sample with a packing ratio of 0.2.
• the sample is subjected to elementary analysis in the conventional method using MT2 CHN CORDER Yanaco, Yanagimoto Mfg. Co., Ltd, with passage of oxygen (helium carrier) at 900 °C.
• the particles were filtered from the dispersion, washed with water, dried and pulverized in a mortar to obtain goethite particles coated with the metal compounds.
• the dispersion was adjusted to pH 10.5 with an aqueous solution of 1N-NaOH and thereto was added an aqueous solution obtained by dissolving a specific amount of the secondly coated metal compound listed in Table 2 in 10 ml of pure water. The mixture was stirred and adjusted to pH 8.5 with 0.2N-HCl to perform the coating of the metal compound.
• Fe5C2 was detected by the peaks having plane spacings at 2.05 ⁇ , 2.08 ⁇ and 2.20 ⁇
• Fe7C3 was detected by the peaks having plane spacings at 2.02 ⁇ , 2.12 ⁇ and 2.26 ⁇ (plane spacings having high intensity were selected in Fe5C2 Iron Carbide on ASTM X-Ray Powder Data File 20-509 and Fe7C3 Iron Carbide on ASTM X-Ray Powder Data File 17-333).
• ratio of Fe5C2 and Fe7C3 was measured from ratio of their intensity in 2.05 ⁇ and 2.02 ⁇ respectively. Table 3 gives magnetic characteristics and the results of the analysis.
• the iron carbide fine particles of Example 1 obtained from the starting iron compound coated with iron compound have a small amount of free carbon
• the iron carbide fine particles of Examples 2 to 4 obtained from the starting iron compound coated with both of iron compound and cobalt compound have a small amount of free carbon and are excellent in coercive force and saturation magnetization.

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• Chemical & Material Sciences (AREA)
• Organic Chemistry (AREA)
• Engineering & Computer Science (AREA)
• Metallurgy (AREA)
• Inorganic Chemistry (AREA)
• Carbon And Carbon Compounds (AREA)
• Hard Magnetic Materials (AREA)
• Compounds Of Iron (AREA)
• Catalysts (AREA)

Applications Claiming Priority (2)

Publications (3)

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ID=16002783

Family Applications (1)

Country Status (7)

Families Citing this family (5)

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• 1990
  • 1990-07-02 JP JP2175819A patent/JPH085651B2/ja not_active Expired - Lifetime
• 1991
  • 1991-07-01 TW TW080105092A patent/TW198707B/zh active
  • 1991-07-01 DE DE69114190T patent/DE69114190T2/de not_active Expired - Fee Related
  • 1991-07-01 US US07/723,887 patent/US5205950A/en not_active Expired - Lifetime
  • 1991-07-01 EP EP91110872A patent/EP0464745B1/en not_active Expired - Lifetime
  • 1991-07-02 CA CA002046047A patent/CA2046047A1/en not_active Abandoned
  • 1991-07-02 KR KR1019910011177A patent/KR940009271B1/ko not_active IP Right Cessation

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